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Komatsu PC600-8, PC600LC-8 Hydraulic Excavator Operation & Maintenance Manual (K50001 and up) - PDF
Komatsu PC600-8, PC600LC-8 Hydraulic Excavator Operation & Maintenance Manual
FILE DETAILS:
Komatsu PC600-8, PC600LC-8 Hydraulic Excavator Operation & Maintenance Manual
File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : UEAM005000
Total Pages : 318
DESCRIPTION:
Komatsu PC600-8, PC600LC-8 Hydraulic Excavator Operation & Maintenance Manual
FOREWORD :
- This manual provides rules and guidelines which will help you use this machine safely and effectively. The precautions in this manual must be followed at all times when performing operation and maintenance. Most accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines.
- Accidents can be prevented by knowing beforehand conditions that may cause a hazard when performing operation and maintenance.
TABLE OF CONTENTS:
Komatsu PC600-8, PC600LC-8 Hydraulic Excavator Operation & Maintenance Manual
FOREWORD........................................................................................................................................................... 4 SAFETY INFORMATION................................................................................................................................................. 5 Signal words................................................................................................................................................... 5 Example of safety message using signal word.................................................................................................................... 5 Other signal words............................................................................................................................................. 5 Example of safety label using words............................................................................................................................ 6 Safety labels using pictogram.................................................................................................................................. 6 NOISE.......................................................................................................................................................... 7 Vibration levels............................................................................................................................................... 8 Operating condition:....................................................................................................................................... 8 Guide to Reduce Vibration Levels on Machine................................................................................................................ 8 INTRODUCTION....................................................................................................................................................... 10 DIRECTIONS OF MACHINE.......................................................................................................................................... 10 VISIBILITY FROM OPERATOR'S SEAT................................................................................................................................ 11 PROXIMITY VISIBILITY....................................................................................................................................... 11 12M CIRCUMFERENCE VISIBILITY............................................................................................................................... 11 BREAKING-IN THE NEW MACHINE.................................................................................................................................... 12 PRODUCT INFORMATION................................................................................................................................................ 13 PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE................................................................................................... 13 ENGINE SERIAL NUMBER PLATE AND ITS LOCATION.................................................................................................................... 13 SERVICE METER LOCATION......................................................................................................................................... 14 YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR.................................................................................................................... 14 MACHINE SERIAL PLATE........................................................................................................................................... 15 FOREWORD................................................................................................................................................... 16 SAFETY..................................................................................................................................................... 16 OPERATION.................................................................................................................................................. 17 MAINTENANCE................................................................................................................................................ 19 SPECIFICATIONS............................................................................................................................................. 21 ATTACHMENTS AND OPTIONS.................................................................................................................................... 22 INDEX...................................................................................................................................................... 22 COLOPHON................................................................................................................................................... 22 SAFETY INFORMATION................................................................................................................................................. 24 SAFETY LABELS...................................................................................................................................................... 26 LOCATION OF SAFETY LABELS...................................................................................................................................... 27 SAFETY LABELS.................................................................................................................................................. 28 SAFETY INFORMATION................................................................................................................................................. 35 SAFETY RULES................................................................................................................................................... 35 IF PROBLEMS ARE FOUND.......................................................................................................................................... 35 WORKING WEAR AND PERSONAL PROTECTIVE ITEMS..................................................................................................................... 35 FIRE EXTINGUISHER AND FIRST AID KIT............................................................................................................................ 35 SAFETY EQUIPMENT............................................................................................................................................... 36 KEEP MACHINE CLEAN............................................................................................................................................. 36 KEEP OPERATOR'S COMPARTMENT CLEAN.............................................................................................................................. 36 LEAVING OPERATOR'S SEAT WITH LOCK.............................................................................................................................. 36 HANDRAILS AND STEPS............................................................................................................................................ 37 MOUNTING AND DISMOUNTING....................................................................................................................................... 38 NO PERSONS ON ATTACHMENTS...................................................................................................................................... 38 DO NOT GET CAUGHT IN ARTICULATED PORTION....................................................................................................................... 38 BURN PREVENTION................................................................................................................................................ 38 FIRE PREVENTION AND EXPLOSION PREVENTION....................................................................................................................... 39 ACTION IF FIRE OCCURS.......................................................................................................................................... 40 WINDSHIELD WASHER FLUID........................................................................................................................................ 40 FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION............................................................................................... 40 ATTACHMENT INSTALLATION........................................................................................................................................ 40 ATTACHMENT COMBINATIONS........................................................................................................................................ 40 CAB WINDOW GLASSES............................................................................................................................................. 41 UNAUTHORIZED MODIFICATIONS..................................................................................................................................... 41 SAFETY AT JOBSITE.............................................................................................................................................. 41 WORKING ON LOOSE GROUND........................................................................................................................................ 41 DISTANCE TO HIGH VOLTAGE CABLES................................................................................................................................ 42 ENSURE GOOD VISIBILITY......................................................................................................................................... 42 VENTILATION FOR ENCLOSED AREA.................................................................................................................................. 43 SIGNALMAN'S SIGNAL AND SIGNS................................................................................................................................... 43 EMERGENCY EXIT FROM OPERATOR'S CAB............................................................................................................................. 43 ASBESTOS DUST HAZARD PREVENTION................................................................................................................................ 43 SAFETY MACHINE OPERATION........................................................................................................................................... 44 STARTING ENGINE................................................................................................................................................ 44 CHECKS BEFORE STARTING ENGINE.............................................................................................................................. 44 SAFETY RULES FOR STARTING ENGINE........................................................................................................................... 45 STARTING ENGINE IN COLD WEATHER............................................................................................................................ 45 OPERATION...................................................................................................................................................... 46 CHECKS BEFORE OPERATION.................................................................................................................................... 46 SAFETY RULES FOR CHANGING MACHINE DIRECTIONS............................................................................................................... 46 SAFETY RULES FOR TRAVELING................................................................................................................................. 47 TRAVELING ON SLOPES........................................................................................................................................ 47 OPERATIONS ON SLOPES....................................................................................................................................... 48 PROHIBITED OPERATIONS...................................................................................................................................... 48 OPERATIONS ON SNOW......................................................................................................................................... 50 PARKING MACHINE............................................................................................................................................ 51 TRANSPORTATION................................................................................................................................................. 52 LOADING AND UNLOADING...................................................................................................................................... 52 SHIPPING THE MACHINE....................................................................................................................................... 52 BATTERY........................................................................................................................................................ 53 BATTERY HAZARD PREVENTION.................................................................................................................................. 53 STARTING ENGINE WITH BOOSTER CABLES........................................................................................................................ 54 TOWING......................................................................................................................................................... 54 SAFETY RULES FOR TOWING.................................................................................................................................... 54 LIFTING OBJECTS WITH BUCKET.................................................................................................................................... 55 SAFETY RULES FOR LIFTING OBJECTS........................................................................................................................... 55 SAFETY MAINTENANCE INFORMATION..................................................................................................................................... 56 WARNING TAG.................................................................................................................................................... 56 KEEP WORK PLACE CLEAN AND TIDY................................................................................................................................. 56 APPOINT LEADER WHEN WORKING WITH OTHERS........................................................................................................................ 56 STOP ENGINE BEFORE CARRYING OUT MAINTENANCE.................................................................................................................... 57 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING............................................................................................................. 57 PROPER TOOLS................................................................................................................................................... 58 ACCUMULATOR.................................................................................................................................................... 58 PERSONNEL...................................................................................................................................................... 58 ATTACHMENTS.................................................................................................................................................... 59 WORK UNDER THE MACHINE......................................................................................................................................... 59 NOISE.......................................................................................................................................................... 59 WHEN USING HAMMER.............................................................................................................................................. 59 WELDING WORKS.................................................................................................................................................. 59 REMOVING BATTERY TERMINALS..................................................................................................................................... 60 SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION........................................................................................... 60 DO NOT DISASSEMBLE RECOIL SPRINGS.............................................................................................................................. 60 SAFETY RULES FOR HIGH-PRESSURE OIL............................................................................................................................. 60 PRECAUTION FOR HIGH FUEL PRESSURE.............................................................................................................................. 61 SAFETY HANDLING HIGH-PRESSURE HOSES............................................................................................................................ 61 PRECAUTION FOR HIGH VOLTAGE.................................................................................................................................... 61 WASTE MATERIALS................................................................................................................................................ 62 AIR CONDITIONER MAINTENANCE.................................................................................................................................... 62 COMPRESSED AIR................................................................................................................................................. 62 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.................................................................................................................. 62 MACHINE VIEW ILLUSTRATIONS......................................................................................................................................... 64 OVERALL MACHINE VIEW........................................................................................................................................... 64 CONTROLS AND GAUGES............................................................................................................................................ 65 DETAILED CONTROLS AND GAUGES....................................................................................................................................... 67 MONITORING SYSTEM.............................................................................................................................................. 67 Basic Operation of Machine Monitor......................................................................................................................... 68 If There Is Abnormality When Starting Engine........................................................................................................... 68 If Any Abnormality Occurs During Operation............................................................................................................. 69 Emergency Monitors......................................................................................................................................... 71 Engine Coolant Temperature Monitor..................................................................................................................... 71 Hydraulic Oil Temperature Monitor...................................................................................................................... 72 Engine Oil Pressure Monitor............................................................................................................................ 72 Caution Monitors........................................................................................................................................... 73 Charge Level Monitor................................................................................................................................... 73 Fuel Level Monitor..................................................................................................................................... 74 Air Cleaner Clogging Monitor........................................................................................................................... 74 Engine Coolant Temperature Monitor..................................................................................................................... 74 Hydraulic Oil Temperature Monitor...................................................................................................................... 74 Basic Check Monitors....................................................................................................................................... 75 Radiator Coolant Level Monitor......................................................................................................................... 75 Engine Oil Level Monitor............................................................................................................................... 76 Maintenance Interval Monitor........................................................................................................................... 76 Meter Display Portion...................................................................................................................................... 77 Pilot Display.......................................................................................................................................... 77 Engine Pre-heating Monitor......................................................................................................................... 77 Swing Lock Monitor................................................................................................................................. 78 Wiper Monitor...................................................................................................................................... 78 Auto-deceleration Monitor.......................................................................................................................... 78 Working Mode Monitor............................................................................................................................... 78 Travel Speed Monitor............................................................................................................................... 79 One-Touch Power Max. Monitor....................................................................................................................... 79 Gauges and Meter....................................................................................................................................... 80 Engine Coolant Temperature Gauge................................................................................................................... 80 Fuel Gauge......................................................................................................................................... 80 Hydraulic Oil Temperature Gauge.................................................................................................................... 81 Service Meter...................................................................................................................................... 81 Monitor Switches Portion................................................................................................................................... 82 Working Mode Selector Switch (Basic Switch)............................................................................................................ 82 Auto-deceleration Switch (Selection Switch)............................................................................................................ 83 Travel Speed Selector Switch (Selection Switch)........................................................................................................ 84 Wiper Switch........................................................................................................................................... 85 Window Washer Switch................................................................................................................................... 86 Maintenance Switch..................................................................................................................................... 86 User Mode Adjustment Switch............................................................................................................................ 88 Fan Reverse Rotation................................................................................................................................... 88 Adjusting Set Value of Economy Mode.................................................................................................................... 91 Back Switch............................................................................................................................................ 92 Up Switch, Down Switch................................................................................................................................. 92 Input Confirmation Switch.............................................................................................................................. 93 Liquid Crystal Monitor Adjustment Switch............................................................................................................... 93 Adjusting Brightness................................................................................................................................... 93 Adjusting Contrast..................................................................................................................................... 94 Alarm Buzzer Stop Switch............................................................................................................................... 95 SWITCHES....................................................................................................................................................... 96 Starting Switch............................................................................................................................................ 96 Fuel Control Dial.......................................................................................................................................... 97 Cigarette Lighter.......................................................................................................................................... 97 Machine Push-up Switch..................................................................................................................................... 97 Lamp Switch................................................................................................................................................ 98 Swing Lock Switch.......................................................................................................................................... 98 Boom Shockless Control Switch.............................................................................................................................. 99 Horn Switch................................................................................................................................................ 99 Room Lamp Switch........................................................................................................................................... 99 Emergency Pump Drive Switch................................................................................................................................100 Swing Brake Cancel Switch..................................................................................................................................100 Revolving Warning Lamp Switch..............................................................................................................................100 Lower Wiper Switch.........................................................................................................................................101 Step Light Switch..........................................................................................................................................101 One-Touch Power Max. Switch................................................................................................................................101 Large Capacity Airflow Air Conditioner Blower Switch.......................................................................................................102 CONTROL LEVERS AND PEDALS......................................................................................................................................103 Lock Lever.................................................................................................................................................103 Travel Levers (with Pedals and Auto-deceleration Device)...................................................................................................104 Work Equipment Control Lever...............................................................................................................................104 SUN ROOF.......................................................................................................................................................106 Opening....................................................................................................................................................106 Closing....................................................................................................................................................106 WINDSHIELD.....................................................................................................................................................107 Opening....................................................................................................................................................107 Closing....................................................................................................................................................110 Removing Lower Windshield..................................................................................................................................111 EMERGENCY EXIT FROM OPERATOR'S CAB.............................................................................................................................112 DOOR LOCK......................................................................................................................................................112 CAP WITH LOCK..................................................................................................................................................113 Opening and Closing Caps with Lock.........................................................................................................................113 Opening the Cap............................................................................................................................................113 Locking the Cap............................................................................................................................................113 Opening and Closing Cover with Lock........................................................................................................................113 Opening the Cover (Locked Cover)...........................................................................................................................113 Locking the Cover..........................................................................................................................................113 HOT AND COOL BOX...............................................................................................................................................114 MAGAZINE BOX...................................................................................................................................................114 ASHTRAY........................................................................................................................................................114 AIR CONDITIONER CONTROLS.......................................................................................................................................115 Air Conditioner Control Panel..............................................................................................................................115 OFF Switch.............................................................................................................................................115 Fan Switch.............................................................................................................................................115 Temperature Control Switch.............................................................................................................................116 Vent Selector Switch...................................................................................................................................116 Auto Switch............................................................................................................................................117 FRESH/RECIRC Selector Switch...........................................................................................................................118 Display Monitor........................................................................................................................................118 Air Conditioner Switch.................................................................................................................................118 Sunlight Sensor........................................................................................................................................119 Method of Operation........................................................................................................................................119 Automatic Operation....................................................................................................................................119 Stopping Automatic Operation...........................................................................................................................120 Manual Operation.......................................................................................................................................120 Stopping Manual Operation..............................................................................................................................122 Operation with Cold Air to Face and Warm Air to Feet...................................................................................................122 Defroster Operation....................................................................................................................................123 Use Air Conditioner with Care..............................................................................................................................125 Ventilation............................................................................................................................................125 Temperature Control....................................................................................................................................125 Inspection and maintenance of Air Conditioner Equipped Machine.............................................................................................125 Other Functions............................................................................................................................................126 Self-diagnostic Function...............................................................................................................................126 Function to Switch Set Temperature Display Between Fahrenheit and Celsius..............................................................................127 CAB RADIO......................................................................................................................................................127 Antenna....................................................................................................................................................127 Use Radio With Care........................................................................................................................................127 AUXILIARY ELECTRIC POWER.......................................................................................................................................128 24V power source...........................................................................................................................................128 12V power source...........................................................................................................................................128 FUSE...........................................................................................................................................................129 Fuse Capacities and Circuit Names..........................................................................................................................129 CIRCUIT BREAKER................................................................................................................................................130 CONTROLLER.....................................................................................................................................................131 TOOL BOX.......................................................................................................................................................131 GREASE PUMP....................................................................................................................................................132 Method of Use..............................................................................................................................................132 Precautions when Using.....................................................................................................................................133 Supplying Grease...........................................................................................................................................133 ACCUMULATOR....................................................................................................................................................135 Releasing Hydraulic Pressure With Accumulator..............................................................................................................135 MACHINE OPERATIONS AND CONTROLS....................................................................................................................................136 BEFORE STARTING ENGINE.........................................................................................................................................136 Walk-around Checks.........................................................................................................................................136 Checks Before Starting.....................................................................................................................................137 Check Coolant Level, Add Coolant.......................................................................................................................137 Check Oil Level in Engine Oil Pan, Add Oil.............................................................................................................138 Check Fuel Level, Add Fuel.............................................................................................................................139 Check for Water and Sediment in Water Separator, Drain Water...........................................................................................140 Drain Water And Sediment from Fuel Tank................................................................................................................141 Check Oil Level in Hydraulic Tank, Add Oil.............................................................................................................141 Check Oil Level in Swing Machinery Case, Add Oil.......................................................................................................142 Check Oil Level in P.T.O Case, Add Oil.................................................................................................................143 Check Working Lamp Switch..............................................................................................................................144 Check Electric Wiring..................................................................................................................................145 Check Function of Horn.................................................................................................................................145 Adjustment.................................................................................................................................................146 Seat Adjustment........................................................................................................................................146 Rearview Mirrors.......................................................................................................................................148 Seat Belt..................................................................................................................................................149 Fastening and Removing.................................................................................................................................149 Fastening Seat Belt....................................................................................................................................149 Removing Belt..........................................................................................................................................149 Operations Before Starting Engine..........................................................................................................................150 STARTING ENGINE................................................................................................................................................153 AFTER STARTING ENGINE..........................................................................................................................................156 Warming Up Engine..........................................................................................................................................156 Warming Up Hydraulic Equipment.............................................................................................................................158 Operation After Completion Of Warming-Up Operation.........................................................................................................162 STOPPING THE ENGINE............................................................................................................................................163 MACHINE OPERATION..............................................................................................................................................164 Preparations for Moving the Machine........................................................................................................................164 Moving Machine Forward.....................................................................................................................................165 Moving Machine Backward....................................................................................................................................166 Stopping Machine...........................................................................................................................................167 STEERING THE MACHINE...........................................................................................................................................168 Steering...................................................................................................................................................168 Steering the Machine when Stopped......................................................................................................................168 Changing Direction of the Machine......................................................................................................................169 Counter-rotation Turn (Spin Turn)......................................................................................................................169 SWINGING.......................................................................................................................................................170 WORK EQUIPMENT CONTROLS AND OPERATIONS.........................................................................................................................171 WORKING MODE...................................................................................................................................................172 Working Mode...............................................................................................................................................172 Setting Economy Mode.......................................................................................................................................173 PROHIBITED OPERATIONS..........................................................................................................................................174 Operations Using Swing Force...............................................................................................................................174 Operations Using Travel Force..............................................................................................................................174 Prohibition of Operations Using Hydraulic Cylinders to Stroke Ends.........................................................................................174 Operations Using Bucket Dropping Force.....................................................................................................................175 Operations Using Machine Dropping Force....................................................................................................................175 Digging Hard Rocky Ground..................................................................................................................................175 Sudden Lever Shifting High Speed Travel....................................................................................................................175 GENERAL OPERATION INFORMATION..................................................................................................................................176 Traveling..................................................................................................................................................176 High Speed Travel..........................................................................................................................................176 Precautions when Carrying Out Operations Continually with the Work Equipment in the Same Posture...........................................................176 Permissible Water Depth....................................................................................................................................177 TRAVELING ON SLOPES............................................................................................................................................178 Traveling Downhill.........................................................................................................................................179 Engine Stopped on Slope....................................................................................................................................179 Cab Doors on Slope.........................................................................................................................................179 ESCAPE FROM MUD................................................................................................................................................180 Track on One Side Stuck....................................................................................................................................180 Tracks on Both Sides Stuck.................................................................................................................................180 RECOMMENDED APPLICATIONS.......................................................................................................................................181 Backhoe Work...............................................................................................................................................181 Ditching Work..............................................................................................................................................181 Loading Work...............................................................................................................................................181 BUCKET REPLACEMENT.............................................................................................................................................182 Replacement................................................................................................................................................182 PARKING MACHINE................................................................................................................................................184 MACHINE INSPECTION AFTER DAILY WORK............................................................................................................................185 LOCKING........................................................................................................................................................186 OVERLOAD WARNING DEVICE (option)...............................................................................................................................186 TRANSPORTATION.....................................................................................................................................................187 PRECAUTIONS FOR TRANSPORTATION.................................................................................................................................187 LIFTING MACHINE................................................................................................................................................187 SHIPPING MACHINE INFORMATION...................................................................................................................................189 TRANSPORTATION POSTURE.........................................................................................................................................190 Three units for transportation.............................................................................................................................190 Posture for Each Unit......................................................................................................................................191 Upper Structure + Undercarriage............................................................................................................................191 Upper Structure............................................................................................................................................191 Undercarriage..............................................................................................................................................191 Work Equipment.............................................................................................................................................192 Others.....................................................................................................................................................193 PROCEDURE FOR INCREASING OR REDUCING TRACK FRAME GAUGE.........................................................................................................195 Reducing Track Gauge.......................................................................................................................................195 Increasing Track Gauge.....................................................................................................................................196 COLD WEATHER OPERATION.............................................................................................................................................197 COLD WEATHER OPERATION INFORMATION.............................................................................................................................197 Fuel and Lubricants........................................................................................................................................197 Cooling System Coolant.....................................................................................................................................197 Battery....................................................................................................................................................198 Monitor....................................................................................................................................................199 AFTER DAILY WORK COMPLETION....................................................................................................................................200 AFTER COLD WEATHER SEASON......................................................................................................................................200 LONG TERM STORAGE..................................................................................................................................................201 BEFORE STORAGE.................................................................................................................................................201 DURING STORAGE.................................................................................................................................................201 AFTER STORAGE..................................................................................................................................................202 STARTING MACHINE AFTER LONG-TERM STORAGE.......................................................................................................................202 TROUBLES AND ACTIONS...............................................................................................................................................203 RUNNING OUT OF FUEL............................................................................................................................................203 Procedure for Bleeding Air.................................................................................................................................203 PHENOMENA THAT ARE NOT FAILURES................................................................................................................................204 TOWING THE MACHINE.............................................................................................................................................205 SEVERE JOB CONDITION...........................................................................................................................................205 DISCHARGED BATTERY.............................................................................................................................................206 Battery Removal and Installation...........................................................................................................................206 Battery Charges............................................................................................................................................207 Starting Engine with Booster Cables........................................................................................................................208 Connecting and Disconnecting Booster Cables............................................................................................................208 Booster Cable Connection...............................................................................................................................209 Starting the Engine....................................................................................................................................209 Booster Cable Disconnection............................................................................................................................209 OTHER TROUBLE..................................................................................................................................................210 Electrical System..........................................................................................................................................210 Chassis....................................................................................................................................................211 Engine.....................................................................................................................................................212 Electronic Control System..................................................................................................................................214 Machine Monitoring System..............................................................................................................................214 Point of Contact to Telephone when Error Occurs............................................................................................................215 MAINTENANCE INFORMATION............................................................................................................................................218 Service Meter Reading..........................................................................................................................................218 Komatsu Genuine Replacement Parts..............................................................................................................................218 Komatsu Genuine Lubricants.....................................................................................................................................218 Windshield Washer Fluid........................................................................................................................................218 Fresh and Clean Lubricants.....................................................................................................................................218 Check Drained Oil and Used Filter..............................................................................................................................218 Fuel Strainer..................................................................................................................................................218 Welding Instructions...........................................................................................................................................218 Do not Drop Things Inside Machine..............................................................................................................................218 Dusty Jobsite..................................................................................................................................................219 Avoid Mixing Lubricants........................................................................................................................................219 Locking the Inspection Covers..................................................................................................................................219 Hydraulic System - Air Bleeding................................................................................................................................219 Hydraulic Hose Installation....................................................................................................................................219 Checks After Inspection and Maintenance Works..................................................................................................................219 OUTLINE OF SERVICE.................................................................................................................................................220 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC.........................................................................................................220 Oil........................................................................................................................................................220 Fuel.......................................................................................................................................................220 Cooling System Coolant.....................................................................................................................................221 Grease.....................................................................................................................................................221 Carrying Out KOWA (Komatsu Oil Wear Analysis)..............................................................................................................222 KOWA Analysis Items....................................................................................................................................222 Oil Sampling...........................................................................................................................................222 Oil and Fuel Storage.......................................................................................................................................223 Filters....................................................................................................................................................223 ELECTRIC SYSTEM MAINTENANCE....................................................................................................................................224 WEAR PARTS.........................................................................................................................................................225 WEAR PARTS LIST................................................................................................................................................225 LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS........................................................................................................................226 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL............................................................................227 TIGHTENING TORQUE SPECIFICATIONS...................................................................................................................................228 TIGHTENING TORQUE LIST.........................................................................................................................................228 SAFETY CRITICAL PARTS..............................................................................................................................................229 SAFETY CRITICAL PARTS LIST.....................................................................................................................................230 MAINTENANCE SCHEDULE...............................................................................................................................................231 MAINTENANCE SCHEDULE CHART.....................................................................................................................................231 INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS).............................................................................................231 INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS).............................................................................................231 WHEN REQUIRED..............................................................................................................................................231 CHECKS BEFORE STARTING.....................................................................................................................................231 EVERY 10 HOURS MAINTENANCE.................................................................................................................................231 EVERY 100 HOURS MAINTENANCE................................................................................................................................231 EVERY 250 HOURS MAINTENANCE................................................................................................................................231 EVERY 500 HOURS MAINTENANCE................................................................................................................................232 EVERY 1000 HOURS MAINTENANCE...............................................................................................................................232 EVERY 2000 HOURS MAINTENANCE...............................................................................................................................232 EVERY 4000 HOURS MAINTENANCE...............................................................................................................................232 EVERY 5000 HOURS MAINTENANCE...............................................................................................................................232 EVERY 8000 HOURS MAINTENANCE...............................................................................................................................232 MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER.....................................................................................................................233 REPLACE HYDRAULIC OIL FILTER ELEMENT.......................................................................................................................233 CHANGE OIL IN HYDRAULIC TANK...............................................................................................................................233 REPLACE ADDITIONAL FILTER ELEMENT FOR BREAKER..............................................................................................................233 MAINTENANCE PROCEDURE..............................................................................................................................................234 INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS).................................................................................................234 INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS).................................................................................................234 WHEN REQUIRED..................................................................................................................................................235 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT...............................................................................................................235 Checking...............................................................................................................................................235 Cleaning or Replacing Outer Element....................................................................................................................236 Install Air Cleaner Element............................................................................................................................238 CLEAN INSIDE OF COOLING SYSTEM.............................................................................................................................240 CHECK AND TIGHTEN TRACK SHOE BOLTS.........................................................................................................................243 Tightening.............................................................................................................................................243 Order for Tightening...................................................................................................................................243 CHECK AND ADJUST TRACK TENSION.............................................................................................................................244 Checking...............................................................................................................................................244 Adjustment.............................................................................................................................................244 Increasing Track Tension...............................................................................................................................244 Loosening Track Tension................................................................................................................................245 REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE).................................................................................................................246 ADJUST BUCKET CLEARANCE....................................................................................................................................247 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID.................................................................................................................248 Mixture Ratio of Pure Washer Fluid and Water...........................................................................................................248 CHECK AND MAINTENANCE AIR CONDITIONER......................................................................................................................249 Check Level of Refrigerant (gas).......................................................................................................................249 Inspection During Off Season...........................................................................................................................249 Inspection and Maintenance Items.......................................................................................................................249 CLEAN LINE FILTER, REMOVE DIRT.............................................................................................................................250 REPLACE BREAKER CIRCUIT ADDITIONAL OIL FILTER ELEMENT......................................................................................................251 CLEAN PILOT LINE FILTER, REMOVE DIRT.......................................................................................................................252 BLEEDING AIR FROM HYDRAULIC SYSTEM.........................................................................................................................253 Operation..............................................................................................................................................255 CHECK BEFORE STARTING..........................................................................................................................................256 EVERY 10 HOURS MAINTENANCE.....................................................................................................................................257 LUBRICATING................................................................................................................................................257 EVERY 100 HOURS MAINTENANCE....................................................................................................................................260 LUBRICATING SWING CIRCLE...................................................................................................................................260 EVERY 250 HOURS MAINTENANCE....................................................................................................................................261 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL...............................................................................................................261 CHECK LEVEL OF BATTERY ELECTROLYTE.........................................................................................................................262 When Checking Electrolyte Level from Side of Battery...................................................................................................263 When it is Impossible to Check Electrolyte Level from Side of Battery..................................................................................263 When it is Possible to Use Indicator to Check Electrolyte Level........................................................................................263 CHECK AND TIGHTEN TRACK FRAME AND AXLE CONNECTING BOLTS....................................................................................................264 CHECK ALTERNATOR DRIVE BELT TENSION, ADJUST................................................................................................................265 Checking...............................................................................................................................................265 Adjustment.............................................................................................................................................265 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST......................................................................................................266 Checking...............................................................................................................................................266 Adjustment.............................................................................................................................................266 EVERY 500 HOURS MAINTENANCE....................................................................................................................................267 REPLACE FUEL PRE-FILTER CARTRIDGE..........................................................................................................................267 CHECK SWING PINION GREASE LEVEL, ADD GREASE................................................................................................................270 CLEAN,CHECK RADIATOR FINS,OIL COOLER FINS,FUEL COOLER FINS,AFTERCOOLER FINS,CONDENSER FINS (machines equipped with air conditioner),PTO OIL COOLER FINS....271 CLEAN FRESH/RECIRC AIR FILTERS OF AIR CONDITIONER (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER)........................................................273 CLEAN RECIRC AIR FILTER................................................................................................................................273 CLEAN FRESH AIR FILTER.................................................................................................................................273 CLEAN STRAINER OF P.T.O LUBRICATING OIL FILTER.............................................................................................................274 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE..........................................................................................275 EVERY 1000 HOURS MAINTENANCE...................................................................................................................................277 REPLACE FUEL MAIN FILTER CARTRIDGE.........................................................................................................................277 REPLACE HYDRAULIC OIL FILTER ELEMENT.......................................................................................................................280 CHANGE OIL IN SWING MACHINERY CASE.........................................................................................................................281 CHANGE OIL IN P.T.O CASE...................................................................................................................................282 CHECK ALL TIGHTENING POINTS OF ENGINE EXHAUST PIPE CLAMPS..................................................................................................283 REPLACE CORROSION RESISTOR CARTRIDGE.......................................................................................................................283 CHECK WELDED STRUCTURE.....................................................................................................................................284 REPLACE HYDRAULIC TANK ADDITIONAL BREATHER ELEMENT.........................................................................................................287 CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (for breaker)............................................................................................287 REPLACE BREATHER ELEMENT IN HYDRAULIC TANK.................................................................................................................288 EVERY 2000 HOURS MAINTENANCE...................................................................................................................................289 CHANGE OIL IN FINAL DRIVE CASE.............................................................................................................................289 CLEAN HYDRAULIC TANK STRAINER..............................................................................................................................290 CHECKING CHARGE PRESSURE OF NITROGEN GAS IN ACCUMULATOR (FOR CONTROL CIRCUIT)..............................................................................291 FUNCTION OF ACCUMULATOR................................................................................................................................291 CHECKING FUNCTION OF ACCUMULATOR.......................................................................................................................292 METHOD OF RELEASING PRESSURE IN HYDRAULIC CIRCUIT......................................................................................................294 CHECK ALTERNATOR, STARTING MOTOR...........................................................................................................................294 EVERY 4000 HOURS MAINTENANCE...................................................................................................................................295 CHECK WATER PUMP...........................................................................................................................................295 REPLACE ACCUMULATOR (FOR CONTROL CIRCUIT)..................................................................................................................295 CHECK FOR LOOSENESS OF HIGH-PRESSURE PIPING CLAMP, HARDENING OF RUBBER.....................................................................................295 CHECK FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER...........................................................................................297 CHECK OPERATING CONDITION OF COMPRESSOR....................................................................................................................297 EVERY 5000 HOURS MAINTENANCE...................................................................................................................................298 CHANGE OIL IN HYDRAULIC TANK...............................................................................................................................298 EVERY 8000 HOURS MAINTENANCE...................................................................................................................................299 REPLACE HIGH-PRESSURE PIPING CLAMP.........................................................................................................................299 REPLACE FUEL SPRAY PREVENTION CAP..........................................................................................................................299 SPECIFICATIONS.....................................................................................................................................................302 GENERAL PRECAUTIONS FOR SAFETY.....................................................................................................................................306 PRECAUTIONS WHEN SELECTING.....................................................................................................................................306 READ THE INSTRUCTION MANUAL THOROUGHLY.........................................................................................................................306 PRECAUTIONS WHEN REMOVING OR INSTALLING........................................................................................................................306 PRECAUTIONS WHEN USING.........................................................................................................................................307 ATTACHMENT GUIDE...................................................................................................................................................308 COMBINATIONS OF WORK EQUIPMENT.................................................................................................................................308 Working Range Diagram......................................................................................................................................309 TRACK SHOES SELECTION..........................................................................................................................................310 Selection..................................................................................................................................................310 HANDLING MACHINES EQUIPPED WITH KOMTRAX........................................................................................................................311 BASIC PRECAUTIONS..........................................................................................................................................311 <A>....................................................................................................................................................315 <B>....................................................................................................................................................315 <C>....................................................................................................................................................315 <D>....................................................................................................................................................315 <E>....................................................................................................................................................315 <F>....................................................................................................................................................315 <G>....................................................................................................................................................315 <H>....................................................................................................................................................315 <I>....................................................................................................................................................315 <L>....................................................................................................................................................315 <M>....................................................................................................................................................315 <O>....................................................................................................................................................315 <P>....................................................................................................................................................315 <R>....................................................................................................................................................316 <S>....................................................................................................................................................316 <T>....................................................................................................................................................316 <V>....................................................................................................................................................316 <W>....................................................................................................................................................316 <Y>....................................................................................................................................................316
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